The Challenge: Costly, Inefficient Foam Packing Process
ISG (Innovative Solutions Group) was using an outdated approach to protect sensitive equipment during transit and storage:
- Open-cell foam absorbed moisture and developed mold, contaminating equipment
- Pelican cases were expensive and oversized for many applications
- Manual foam cutting required temporary labor, inconsistent quality and high cost
- Spray adhesives were used to assemble foam inserts, messy, time-consuming, and hazardous
This process was costing ISG over $100,000 per year in materials, labor, and rework.
The CIS Solution: Engineered Die-Cut Foam Cases
CIS designed a complete replacement system addressing every pain point:
Custom Die-Cut Closed-Cell Foam
| Component | Details |
|---|---|
| Material | Closed-cell foam, moisture-resistant, mold-proof |
| Design | Custom die-cut to exact equipment dimensions |
| Assembly | Fully pre-assembled, no spray adhesive or manual cutting |
| Cases | Switched from Pelican to Underwater Kinetics, right-sized and cost-effective |
Why Closed-Cell Foam?
Unlike open-cell foam (which acts like a sponge), closed-cell foam has sealed cells that:
- Resist moisture, no water absorption, no mold growth
- Provide superior protection, higher density means better shock absorption
- Last longer, won't degrade or break down over time
- Stay clean, non-porous surface is easy to wipe down
Why Underwater Kinetics Over Pelican?
CIS recommended Underwater Kinetics cases as a cost-effective alternative to Pelican:
- Right-sized options, better fit for ISG's specific equipment
- Comparable protection, meets the same mil-spec durability standards
- Lower cost per unit, significant savings at volume
- Lighter weight, easier handling for field technicians
The Results
The transformation delivered dramatic cost savings and operational improvements:
Key Stats
| Metric | Result |
|---|---|
| 💰 Annual Savings | $104,400 in combined material, labor, and rework savings |
| 📅 Monthly Savings | $8,700 per month |
| 👷 Temp Labor | Eliminated entirely, no more manual foam cutting |
| 🧪 Spray Adhesives | Eliminated, pre-assembled inserts require no glue |
Additional Benefits
- Zero mold issues, closed-cell foam prevents moisture absorption entirely
- Consistent quality, die-cut precision replaces manual cutting variability
- Faster pack times, pre-assembled inserts drop directly into cases
- Reduced waste, optimized foam nesting minimizes material scrap
- Improved field readiness, equipment arrives clean and properly protected
Why It Worked
CIS's engineering-driven approach solved the problem at its foundation:
- Material science, closed-cell foam eliminated the root cause of mold
- Precision manufacturing, die-cutting ensured exact fit every time
- Case optimization, Underwater Kinetics provided the right protection at the right price
- Process elimination, pre-assembly removed temp labor and adhesive steps entirely
"CIS didn't just save us money, they eliminated problems we'd been living with for years.", ISG Operations
Download the Full Case Study
📄 Download the ISG Case Study (PDF)
Explore Our Solutions
Need custom foam protection for your equipment? CIS engineers solutions for any application:
- Die-Cut Foams - Custom foam inserts, kitting, and protective packaging
- Protective Packaging - Comprehensive protection for sensitive equipment
- Packaging Materials - Complete packaging solutions
- Material Handling - Cases, containers, and transport solutions